Development of a robotic maintenance system for wind turbine blades

Project Information

Romain

Grant agreement ID: 101070320

DOI

10.3030/101070320

Project closed

EC signature date 13 June 2022

Start date 1 September 2022

End date 31 May 2026

Funded under

• Digital, Industry and Space

Total cost

€ 2 653 362,50

EU contribution

€ 1 981 831,00

Coordinated by

CNET CENTRE FOR NEW ENERGY TECHNOLOGIES SA
Portugal

Periodic Reporting for period 1 - Romain (Development of a robotic maintenance system for wind turbine blades)

Reporting period: 2022-09-01 to 2024-02-29

Summary of the context and overall objectives of the project

Wind energy plays a central role in tacking climate change, with global installed capacity expected to reach 2 TW by 2030. After installation, wind turbines are expected to run around 20-25 years, during which O&M (operation and maintenance) becomes crucial in maximising the economic and environmental benefits of wind assets. Current maintenance is performed by humans via rope access dangling in the sky along wind turbine blades (WTB) which is both dangerous and low in efficiency. The ultimate solution is a robotic system to avoid the need of humans working in the sky.
Romain, an ambitious collaborative endeavour, seeks to revolutionize the maintenance of WTBs, through the development of an innovative robotic solution. Traditional inspection methods, such as drone-based techniques, are limited to surface defect detections, unable to address subsurface issues. To bridge this gap, Romain integrates cutting-edge technologies, including lock-in shearography and thermography with laser heating, to identify and quantify both surface and subsurface defects WTBs. Complementing the inspection unit, Romain's repair capabilities encompass tasks like applying composite repair patches and conducting heating and compaction curing and consolidation, in a compact and efficient robotic system. This system is operated remotely by engineers on the ground or aboard vessels, significantly reducing risk exposure.
Driven by EDP Labelec, an end-user in the wind energy sector, the project brings together the expertise of three innovative SMEs: Aerones specializes in robotic deployment systems, Front Technologies focuses on advanced inspections, and Alerion contributes expertise in artificial intelligence and machine learning. This collaborative effort is further strengthened by the involvement of University of Leeds and a research and technology organization (Tecnalia) specializing in composite repair.
This project aligns with key priorities in the European wind energy sector, including reducing O&M costs, enhancing safety, retaining technological leadership, promoting export competitiveness and contributes to the European Commission's commitment to a net-zero economy by 2050. Romain's impact extends beyond its immediate objectives, advancing robotics solutions in harsh environments and integrating advanced optical inspection techniques into robotic systems. This not only addresses current wind turbine maintenance challenges but also paves the way for future developments in the renewable energy sector.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The project began in late 2022. A disruption occurred when the original robotic solution provider faced financial difficulties, necessitating a new partner. Aerones Inc. was identified as the best replacement, but their involvement started after the period covered by this analysis (M1-M18). Despite the initial partner bankruptcy, the project team stayed committed to its objectives, actively seeking a solution to the challenge. Notwithstanding this obstacle, significant progress has been made during the reporting period:
-Integration of shearography and thermography with a high-power laser source for efficient and safe heating has been successfully implemented. A new procedure for achieving rapid inspection results has been formulated. Further improvements in both hardware and software are ongoing to facilitate system integration with a robot platform.
-For repair optimization, significant progress has been made:
* A preliminary design concept for the device to be integrated into the robotic platform was developed. Based on a patented combined handling/compaction system, a simplified tooling has been created to evaluate its suitability as an end effector for the Romain repair platform.
* The roadmap on how to design the heating element has been confirmed, and the heat generation and temperature distribution of some designs were computationally simulated with COMSOL Multiphysics. Additionally, different steel meshes with various dimensions were selected as heating elements for welding tests.
-For repair optimization, a preliminary design concept for the device to be integrated into the robotic platform has been developed. Based on a patented combined handling/compaction system, a simplified tooling has been created to evaluate its suitability as an end effector for the Romain repair platform.
-The state-of-the-art for thermographic and shearography images of WTB has been thoroughly studied and analyzed. A processing pipeline framework has been outlined, and graphical representations developed. Initial tests with machine learning algorithms have been conducted to validate their potential for defect identification. An initial database is being constructed to further refine and test these algorithms.
Despite the challenges faced, the project has demonstrated resilience and continues to make significant strides towards its objectives.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The project aims to achieve advancements that could surpass the current state of the art in WTB maintenance. For the inspection system, one advancement is that inspection can be made during the laser heating period, which resulted in rapid inspection of a relatively large area in a few seconds. While the integration of advanced inspection techniques such as lock-in shearography and thermography with laser heating is underway, definitive testing of the integration's success has not yet been completed. Progress has also been made in repair optimization, including the development of innovative heating element designs and the selection of suitable materials for welding tests. These developments have the potential to enhance the efficiency and effectiveness of wind turbine maintenance, leading to reduced downtime and operational costs if successful.
As per potential impacts, the project's outcomes have the potential to have far-reaching impacts on the wind energy sector and beyond. By improving the inspection and repair processes for WTB, the project aims to reduce O&M costs, improve safety conditions for maintenance personnel, and maintain Europe's technological leadership in renewable energy. Additionally, the project's advancements in optical inspection techniques and composite material processing could have broader applications beyond the wind energy sector, contributing to advancements in non-destructive testing and material characterization.
As an ongoing project, continued collaboration and coordination with the new partner, Aerones Inc., are crucial to ensure the successful uptake of the project's results. Research and development efforts are ongoing to refine and optimize the inspection and repair technologies. Testing and validation of the integration of advanced inspection and repair techniques are in progress to confirm their effectiveness.

Project Logo